How to Weld Galvanized Metal

Written by justin obrien
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Many hobbyists prefer to make repairs themselves. When it comes to welding galvanised metal, this can be especially tricky. Practice welding on scrap metal identical to the surface to be welded, and then perform the weld on the finished product. With the proper equipment and the right information, even a novice can turn out a professional-looking job.

Skill level:

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Things you need

  • Wire brush
  • Grinder with disc or wire wheel attachment
  • MIG Welding Machine
  • Welding gloves
  • Welding goggles or helmet
  • Optional Items:
  • Scrap metal for practice
  • Fan
  • Clamps to secure pieces to be welded

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  1. 1

    Clear the work area below and behind where you will be welding of all potentially flammable material.

  2. 2

    Strip a spot near the surface to be welded using a wire wheel or wire brush where you will attach your grounding cable.

  3. 3

    Clean the surface(s) to be welded using a grinder for metal more than ¼ inch thick or a wire wheel for metal less than ¼ inch thick.

  4. 4

    Attach the grounding cable clamp.

  5. 5

    Set the controls on the welding machine as prescribed in the owners manual for the specifications of galvanised metal.

  6. 6

    Perform the weld by pulling the trigger on the welder handle just above where you want to start the weld. It may require several passes. Allow the metal to cool between passes to avoid warping or burning a hole in the metal.

  7. 7

    Inspect the area beneath and behind the surface welded for embers that could cause a fire.

  8. 8

    Clean the weld with a wire wheel or wire brush.

Tips and warnings

  • Make sure the area you are welding in is well ventilated. The zinc used in the galvanising process is toxic and can have adverse health effects. Use a fan if necessary. Make sure the area below and behind the surface you are welding is free of flammable material as molten metal, sparks and slag will ignite almost anything flammable upon contact.

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